Wall structure of panels and interlocking tie rails



Mardi l20, 1.962v

Filed Nov. 5. 1956 J. MUHR WALL lSTRUCTURE OF PANELS AND INTERLOCKING TIERAILS J. MUl-Wi wALL STRUCTURE oF PANELs AND TNTERLOCKING TIE RAILS Filed Nov. 5. 195e 3 Sheets-Sheet 2 IN V EN TOR.

JOHN MU/-E March 20, 1962, J. MUHR u 3,025,640

WALL STRUCTURE OF PANELS AND INTERLOCKING TIE RAILS Filed Nov. 5. 195e 3 Sheets-'Sheet 3 INVENTOR. JOHN MUHI? www 3,025,640 WALL STRUCTURE F PANELS AND INTER- IJCKING TIE RAILS .lohn Mahr, 650 SW. 62nd Court, Miami, Fla. Filed Nov. 5, 1956, Ser. No. 620,539 3 Claims. (Cl. 50-186) This invention relates to a building and more particularly to a building wherein the component parts thereof have been prefabricated, so as to expedite the erection of the building and to reduce the number of parts that are generally used in erecting a building from masonry, although not necessarily so limited.

In the erection of a building, the generally accepted method, with few exceptions, consists of using standard building materials, such as brick and lumber wherein the parts are assembled individually, possibly in sections, the sections being constructed from brick or lumber, each section having been assembled in a factory by production methods.

An object of this invention is to provide preformed cast masonry parts adapted to interlock each other and held in interlocked position by other preformed parts or by suitable locking members, one or two members being used to interlock large sections. This has been accomplished by providing panel-like members having projections or lugs adapted to interlock with other sections having similar lugs but arranged in staggered relation, all of the lugs being provided with apertures through which a fastening member may be inserted.

Other objects and advantages reside in the construction of parts, the combination thereof, the method of manufacture and the mode of operation, as will become more apparent from the following description.

Referring to the drawings, FIGURE l is an elevation view of the entire side of an interior wall showing the iloor and the joists in section.

FIGURE 2 is a cross sectional view, taken substantially on the line 2-2 of FIGURE 1.

FIGURE 3 is a cross sectional View, taken substantially on the line 33 of FIGURE l.

FIGURE 4 is a cross sectional View, taken substantially on the line 44 of FIGURE 1.

FIGURE 5 is a side elevational view of the curved corner section.

FIGURE 6 is an end elevational view of the corner section.

FIGURE 7 is a cross sectional view, taken substantially on the line 7-7 of FIGURE 5.

FIGURE 8 is an exploded view of the parts forming the door frame, or, for that matter, it could be a window frame.

FIGURE 9 is a perspective View of a wall assembly with parts broken away.

FIGURE l0 is a perspective view of a dovetail tie rail.

FIGURE 11 is a perspective view of a pair of foundation blocks.

The disclosure in this application is related to the disclosure in my copending application Serial No. 167,969, filed Iune 14, 1950, for Wall Structure of Panels and Posts, now Patent No. 2,795,949.

In the drawings, the reference character 30 indicates a foundation wall or footing which may consist of any suitable material that is used for foundations. It may be poured concrete, it may consist of masonry or, in the event the building is built on rock, it could be natural rock.

On top of this foundation 30 is mounted a pair of what might be referred to as foundation blocks 32 and 34, as clearly shown in FIGURE 2. These blocks, along with States C l 3,025,640 Patented Mar. 20, 1962 the other blocks et cetera comprising the wall assembly are preferably manufactured as precast. concrete aggregates, although other materials such as glass, plastic, and iibrous compositions may from time to time be employed.

The foundation blocks 32 and 34 enclose an air cell for the purpose of insulation. As may best be seen by referring to FIGURE 11, each of the blocks 32 and 34 is provided with notches in the ends, the notches being positioned between apertured extensions. or lugs 40, 42, 44 and 46. The lug 40 in one end is aligned with a notch 40A in the opposite end, a notch 44A is opposite the lug 44, et cetera. Each of the blocks 32 and 34 is also provided with rows of vertically spaced apertured lugs 48 projecting laterally from the inner surface thereof, the lugs 4S in opposing blocks 32 and 34 being adapted to intermesh as illustrated in FIGURE 2.

The lugs 46, 42, 44, 46, and 48 are tapered slightly, with the notches such as 40A and l44A having a complementary opposite taper. This taper is essential when the panels are to be cast or molded panels and further aids in the assembly of the panels, facilitating the meshing of the lugs. This taper is also provided on the lugs associated with other types of panels as will be described hereinafter.

The block 34 is provided with a joist bed or support 50 and is also provided with flanges or ribs 52, used for supporting the floor, which will appear more fully from the description that follows. The upper margins of the blocks 32 and 34 are provided with tapered anges 33 and 35 which cooperate to form a dovetailed channel 54. This channel diverges as it progresses inwardly between the blocks 32 and 34.

The blocks 32 and 34 are preferably laid in mortar, not shown, or any cementitious material may be used instead of mortar for holding the blocks in position. Adjacent coplanar blocks in the foundation wall are locked together by passing a suitable pin or rod enclosed by an insulating layer through the apertures in the interlocking lugs. Opposing coplanar blocks 32 and 34 are locked together by passing a suitable pin or rod enclosed by an insulating layer through the apertures in the vertical rows of intermeshing lugs 48 therebetween.

In the event the blocks are used for internal partitions, then two blocks 34 are placed side by side, so that both sides will contain floor supporting ribs 52, as clearly shown in FIGURE 3.'

The wall proper, whether it be an exterior wall or an interior wall, consists of panel members 60 and 62. These panel members may be interchangeable. Each of the panel members is provided with a plurality of extensions or lugs 64 and 66. These lugs are bounded on each side by notches 64A and 66A. The height of a notch is equal to the height of a lug. As may readily be seen from the disclosure in FIGURE l, the lugs of one panel are seated in the notches of an adjacent panel. Each of the lugs is provided with a vertically disposed tapered aperture 68. The panels are also provided. with inwardly directed lugs '70 registering with notches in the adjacent panel, that is, half of the lugs extend inwardly from one panel and the other half extend outwardly from the other panel, these lugs also being provided with tapered apertures 68 identical to those already described. These lugs 70 hold the panels in fixed spaced relation with respect t0 each Other. The lugs 64 and 66 interlock adjacent panels or a corner frame or a partition post or a door frame or a window frame, as the case may be. Tapering pins or rods 80, that are preferably enclosed with insulating material 82, extend through the apertures 68 to fixedly lock the panels together, the construction being such that the aligned apertures 68 taper uniformly from top to bottom or the panels.

As may best be seen by referring to FIGURE 2, a key rail or tie rail 36 having oppositely directed outwardly diverging dovetailed projections 85 and 87 is seated in the complementary dovetailed channel 54, found between the blocks 32 and 34 or between adjacent blocks 34, and seated in complementary dovetailed channels 88 formed between the lower margins of the panel members. The panel members 60 and 62 are rabbeted at the lower ends thereof so as -to provide downwardly projecting flanges 84, portions of which are tapered so as to form inwardly diverging walls for the dovetailed channels 88. Likewise, the panels 61)' and 62 are rabbeted at the upper ends thereof so as to provide upwardly directed flanges 89, which cooperate to form inwardly diverging dovetailed channels extending along the top of the panels. rl `he key rail 86 is provided with laterally disposed anges resting upon the upper surface of the blocks 32 and 34 and providing a seat for the lower margins of the panel members 60 and 62.

The central portion of the inner wall of each panel 60 and 62 is hollowed out or recessed, so that when the panels are secured together in opposing relation, an air cell 911 is created therebetween. The rib portions 91 surrounding the air cell are coated with a suitable adhesive during assembly of the panels, to make the air cell 91) air tight. A valve 93 is provided in the wall of each panel 60 to provide for evacuation of the air cell for improved insulation.

Corner members 92 and 94 have been shown in FIG- URE 7. These may form square corners or they may 4form round corners, as shown in this particular gure. The block members 92 and 94 are provided with lateral lugs 96 and 98 corresponding in spacing and in size to the lugs 64 and 66. These blocks 92 and 94 also have inwardly directed lugs 100 and 162. These correspond to the lugs 70 of the panel member. These lugs 100 and 102 are used in holding the blocks together. The lugs '96 and 98 are used in holding the corner blocks to the panel members adjacent 4the corner. The corner block is provided with air cells 104. The upper and lower mar- ;'gins of the corner blocks are provided with dovetailed channels for interlocking engagement through a tie rail with complementary foundation blocks.

In the event a door or a window is desired, spaces between adjacent pairs of panel members 60 and 62 may be left vacant. A door frame member, consisting of uprights 110 and 112 and a lintel member 114, is interlocked with the panel members. An exploded view of the door frame has been shown in FIGURE 8. The side frame members or uprights 110 and 112 are provided with lugs 116 and 11S staggered with respect to each other and subtended by notches 120. These notches receive lugs or extensions 64 and 66 of the panel members, or 'the lugs 96 and 98 if the door is next to a corner post formed by the blocks 92 and 94. The tops of the door frame members 110 and 112 are mitered, so as to receive the lintel member 114. The upper portion of the lintel member 114 consists of a member 130 having outwardly diverging dovetailed portions projecting laterally from the door frame. The lower dovetailed portions of member 130 are seated in the complementary dovetailed channels formed along the top margin of the panel members. The upper dovetailed portion of member 130 is seated in a complementary dovetailed channel formed in plate blocks 132. Both the inner and the outer plate blocks are identical and, that being the case, the same reference numerals have been used for the two. As may be seen in the elevational view of FIGURE 1, the blocks 132, are provided with lugs 134 and 136, subtended by notches 138. The lugs 134 and 136 are apertured and receive tapered pins enclosed with an insulation layer, not shown, @X'fl'ldng through the apertures to hold the parts together. Opposing blocks 132 are locked together with intermeshing laterally projecting lugs 144 in a manner analogous to the interlocking of opposing foundation blocks 32 and 34. A key rail 140y is positioned in the dovetailed channels in the upper margins of the panels 66 and 62 and seated in the lower dovetailed channel formed by tapered flanges 142 at the base of the plate blocks 132, this key rail 141i abutting the ends of the projections 130. The plate blocks 132 support a suitable ceiling and roof structure, not shown.

As clearly shown in FIGURE l, joist members are mounted on the joist beds 56. These joist members 15) are each provided with laterally extending ribs 154, the upper surfaces of which are flush with the upper surface of the ribs 52. These joists 156 may be made of any suitable material, as for example, reinforced concrete.

Floor panels 160, provided with downwardly detlected flanges 162, rest upon the ribs 52 and the laterally disposed ribs 154 of the joists. The ilanges 162 of the floor panels 160 diverge outwardly from the bottom of the oor panels, so as to be seated adjacent the dovetailed ribs 156 extending upwardly from the joists 156, the upper surfaces of which are flush with the upper surface of the floor. After the floor panels have been laid, the crevices between the dovetailed upwardly directed ribs 156 and the flanges 162 may be closed or filled with any suitable sealing material, as for example, mortar, or a mastic material, so as to have a smooth continuous floor.

In the event a ceiling or sub-flooring is to be used, panels like those shown in FIGURE 1, may then rest upon the lower ribs 152 of the joists 150, the panels being provided with rabbets for receiving the ribs 152. Thus, a ceiling may be provided that is flush with the lower margin of the joists.

Although the preferred embodiment of the device has been described, it will be understood that within the purview of this invention various changes may be made in the form, details, proportion and arrangement of parts, the combination thereof and mode of operation, which generally stated consists in a device capable of carrying out the objects set forth, as disclosed and dened in the appended claims.

Having thus described my invention I claim:

1. In a prefabricated mortarless wall construction comprising a plurality of pairs of opposing upright wall panels arranged in side by side relation between a lower foundation assembly and an upper plate assembly, said wall panels providing a double planar wall, each said panel having vertically spaced apertured lugs along the vertical margins thereof, the lugs of adjacent coplanar panels meshing in a vertical row whereby adjacent panels interlock, each said panel being further provided with a vertical row of spaced apertured lugs on the interior surface thereof, the lugs on the interior surfaces of opposing panels meshing whereby opposing panels interlock, the apertures in said vertical rows of meshing lugs being aligned so as to provide a vertical hole in each said vertical row of meshing lugs, and a plurality of rod means, there being one said rod means disposed in the hole of each said vertical row of meshing lugs whereby opposing panels of a pair and adjacent pairs of panels are locked together, the improvement comprising a rabbeted inner corner at the top and bottom extremities of each said wall panel, said rabbeted inner corner including a first planar surface in substantially right angular relationship to the plane of said panel and an intersecting second planar surface in acute angular relationship to said first planar surface and to the plane of said wall panel, the rabbeted inner corners of opposing panels forming a dovetail channel in the top and bottom of said planar wall extending over the length thereof, and a pair of horizontal tie rails, each tie rail having a projection integral therewith, the projection having a crosssection complementary with the dovetail channel formed in the top and bottom of said planar wall, there being an upper tie rail at the top of said planar wall having the complementary dovetail projection thereof engaging the dovetail channel at the top of said wall and a lower tie rail at the bottom of said wall having the complementary dovetail projection thereof engaging the dovetail channel at the bottom of said wall, said upper and lower tie rails being provided with means for interlocking with said plate assembly and said foundation assembly respectively.

2. A prefabricated mortarless construction comprising, in combination, a plurality of wall panels, foundation blocks and plate blocks, said foundation blocks being arranged in two separate parallel opposing horizontal rows, each said foundation block having a vertical column of spaced apertured lugs at each vertical margin thereof, the lugs of adjacent blocks in a row meshing with the apertures thereof in registery so as to provide a vertical hole in each colurne of meshing lugs, said wall panels being arranged in opposing upright pairs disposed in side by side relation above said foundation blocks to provide a planar wall section, each said wall panel having a vertical column of spaced apertured lugs along each vertical margin thereof, the lugs of adjacent coplanar panels meshing with the apertures thereof in registry so as to provide a vertical hole in each vertical column of meshing lugs, each wall panel being further provided with a vertical column of apertured lugs on the interior surface thereof, the interior lugs of opposing panels of a pair meshing with the apertures thereof in registry so as to provide a vertical hole in each vertical column of meshing lugs between each pair of opposing panels, said plate blocks being arranged in two separate parallel opposing rows above said wall panels, each said plate block having a vertical column of apertured lugs at each vertical margin thereof, the lugs of adjacent plate blocks in a row meshing with the apertures thereof in registry so as to provide a vertical hole in each column of meshing lugs, rod means disposed in each said vertical hole whereby adjacent foundation blocks in each row thereof are locked together and adjacent coplanar and opposing parallel wall panels are locked together and adjacent plate blocks in each row thereof are locked together, means including a rabbeted inner corner at the top extremity of each foundation block and the bottom extremity of each plate block and at the top and bottom extremities of each wall panel, said rabbeted inner corner including a iirst planar surface in substantially right angular relationship to the plane of said panel and blocks, and an intersecting second planar surface in acute angular relationship to said rst planar surface and to the plane of said panel and blocks, the rabbeted inner corners of opposing panels and blocks forming dovetail channels in the extremities of wall sections formed by the panels and blocks, and a pair of horizontal tie rails, each tie rail having a pair of opposed projections integral therewith, each projection having a cross-section complementary with said dovetail channels, said means providing a rst dovetail channel along the top of said foundation blocks, said means providing a second opposing dovetail channel along the bottom of said coplanar wall section, a first horizontal tie rail disposed between said foundation blocks and said wall panels and having said oppositely directed dovetail projections engaging said first and second dovetail channels respectively whereby said wall panels are locked to said foundation blocks, said means providing a third dovetail channel along the top of said planar wall section, said means providing a fourth opposing dovetail channel along the bottom of said plate blocks, and a second tie rail disposed between said plate blocks and said Wall panels and having said oppositely directed dovetail projections engaging said third and fourth dovetail projections engaging said third and fourth dovetail channels respectively whereby said plate blocks are locked to said wall panels.

3. In a prefabricated mortarless wall construction, the combination including a pair of upright wall panels disposed in parallel opposing relation, each panel having spaced lugs in that surface thereof which is opposite the other panel, the lugs of said panels meshing one with the other, means passing through said meshing lugs to interlock said panels in fixed relation, each said panel having a rabbeted inner corner at the top and bottom extremities thereof, said rabbeted inner corner including a first planar surface in substantially right angular relationship to the plane of said panel and an intersecting second planar surface in acute angular relationship to said rst planar surface and to the plane of said panel, the rabbeted inner corners of a pair of opposing panels forming a dovetail channel in the top and bottom of said pair of opposing panels extending over the length thereof, and a pair of dovetail tie rails, each tie rail having a projection integral therewith, said projection having a cross-section complementary with said dovetail channel formed in the top and bottom of said pair of opposing panels, there being one tie rail secured in the dovetail channel formed at each of the ends of the interlocked panels.

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